Removable tab and battery assembly having the same

ABSTRACT

A battery assembly includes a battery that has a top surface surrounded by a circumferential edge; and a removable tab attached to the top surface. The removable tab includes a first tab end and an oppositely disposed second tab end; a gripping region disposed adjacent to the first tab end; and a battery cell attachment region disposed adjacent to the second tab end and attached to the top surface of the battery. The battery cell attachment region has first and second oppositely disposed sidewalls, wherein the second tab end is curved inwardly away from the circumferential edge of the battery such that a portion of the top surface of the battery is exposed between the second tab end and the circumferential edge of the battery

BACKGROUND Field of the Disclosure

The disclosure generally relates to removable tabs for batteries andbattery assemblies having the same, and more particularly to a removabletab that facilitates exposure of a portion of the top surface of thebattery.

BRIEF DESCRIPTION OF RELATED TECHNOLOGY

Over the last 15 years, the number of individuals with hearing loss hasnearly doubled. Many suffering from hearing loss are elderly, and, handfunction decreases with age in both men and women, especially after age65. This loss of hand function can make it more difficult to replacehearing aid batteries, even with the use of tabs such as EasyTab®(Duracell U.S. Operations, Inc.), which are relatively long tabs thatare adhered to the batteries to facilitate handling by consumers.Conventional hearing aid tabs, such as EasyTab®, are typically attachedto the battery such that the entire top surface of the battery iscovered by and adhered to the tab. Despite the fact that the relativelylong tab facilitates insertion of the battery by the consumer into thehearing aid, inserting the battery in the hearing aid continues topresent handling challenges, including frequent inadvertent dropping ofthe batteries and associated tabs, and thus can cause significantconsumer frustration, particularly for elderly consumers.

SUMMARY

The invention provides a battery tab structured and arranged forfacilitating removal of the tab from the battery once the battery isplaced in its desired position, such as in a hearing aid.

In accordance with an embodiment of the disclosure, a battery assemblyincludes a battery that has a top surface surrounded by acircumferential edge; and a removable tab attached to the top surface.The removable tab includes a first tab end and an oppositely disposedsecond tab end; a gripping region disposed adjacent to the first tabend; and a battery cell attachment region disposed adjacent to thesecond tab end and attached to the top surface of the battery. Thebattery cell attachment region has first and second oppositely disposedsidewalls and the second tab end is disposed inwardly away from thecircumferential edge of the battery such that a portion of the topsurface of the battery is exposed between the second tab end and thecircumferential edge of the battery.

In accordance with another embodiment, a removable tab includes a firsttab end and an oppositely disposed second tab end; a gripping regiondisposed adjacent to the first tab end; and a battery cell attachmentregion disposed adjacent to the second tab end and attached to the topsurface of the battery. The battery cell attachment region having firstand second oppositely disposed sidewalls and the second tab end isdisposed inwardly away from the circumferential edge of the battery suchthat a portion of the top surface of the battery is exposed between thesecond tab end and the circumferential edge of the battery.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a battery assembly in accordance with anembodiment of the disclosure;

FIG. 2 is a front view of a battery assembly in accordance with anembodiment of the disclosure;

FIG. 3 is a rear view of a battery assembly in accordance with anembodiment of the disclosure;

FIG. 4 is a side view of a battery assembly in accordance with anembodiment of the disclosure;

FIG. 5 is a top view of a battery assembly in accordance with anembodiment of the disclosure;

FIG. 6 is a bottom view of a battery assembly in accordance with anembodiment of the disclosure;

FIG. 7 is a perspective view of a battery assembly in accordance withanother embodiment of the disclosure;

FIG. 8A is a top view of a battery tab in accordance with an embodimentof the disclosure and FIG. 8B is a bottom view of the tab;

FIG. 9A is a top view of a battery tab in accordance with an embodimentof the disclosure and FIG. 9B is a bottom view of the tab; and

FIG. 10A is a schematic illustration of a conventional battery tab andFIG. 10B is a schematic illustration of a tab in accordance with anembodiment of the disclosure, illustrating various dimensions of thetab.

DETAILED DESCRIPTION

Referring to FIG. 1, a battery assembly 10 in accordance with anembodiment of the disclosure includes a battery 12 having a top surface14 and a removable tab 16 attached to the top surface 14 of the battery12.

The removable battery tab 16 disclosed herein can be utilized with anysuitable battery type and/or size. For example, the battery can be ahearing aid battery. In one aspect, the hearing aid battery is ametal/air battery, for example, the hearing aid battery can be a zincair button cell. Additionally, as is known in the art, button cells comein a variety of sizes. Dimensions of the removable tab 16 can beadjusted depending on the size of the battery to which it is attached.Such adjustment can include modification of the width and/or length ofthe battery attachment region of the tab. Additionally, oralternatively, the overall tab length can be adjusted as neededdepending on the battery size. In accordance with embodiments of thedisclosure, a battery assembly is provided, including the battery and aremovable tab. In accordance with other embodiments, a removable tab isprovided for subsequent attachment to a battery.

Referring to FIG. 1, the battery 12 includes the top surface 14surrounded by a circumferential edge 15. The removable tab 16 includes afirst tab end 18 and an oppositely disposed second tab end 20. Theremovable tab 16 includes a gripping region 22 disposed adjacent to thefirst tab end 18 and a battery cell attachment region 24 disposedadjacent to the second tab end 20. The gripping region 22 is a portionof the removable tab 16 that is not coextensive with the battery cellattachment region 24. More specifically, the gripping region 22 does notoverlap with any portion of the removable tab that is coextensive withthe first surface 14 of the battery 12. The battery cell attachmentregion 24 is attached to or adapted to be attached to the top surface 14of the battery 12. The battery cell attachment region 24 of the tab 16includes first and second oppositely disposed sidewalls 26, 28. At leastone of the sidewalls 26, 28 is disposed inwardly from thecircumferential edge 15 of the battery 12 such that a portion 30 of thetop surface 14 of the battery is exposed between the edge 26, 28, 29 ofthe tab 16 and the circumferential edge 15 of the battery 12. In theillustrated embodiment, both sidewalls 26, 28 are curved inwardly fromthe circumferential edge 15 of the battery 12 such that a portion 30 ofthe top surface 14 of the battery is exposed between the edge 26, 28, 29of the tab 16 and the circumferential edge 15 of the battery 12. Othernon-curved means of disposing the edge 26, 28, 29 inwardly away from thecircumferential edge 15 are also contemplated herein. For example, theedge 26, 28, 29 can have a substantially linear edge, with the linearsidewall edge being disposed inwardly away from the circumferential edge15. The exposed surface 30 advantageously provides a region that theuser can depress to maintain the battery 12 in the desired locationwhile concurrently applying a peel force to remove the tab 16 from thebattery 12. Referring to FIGS. 4 and 6, the gripping region 22 isparallel to the plane of the top surface 14 of the battery 12.

Referring to FIG. 5, in various embodiments, the at least one edge 26,28, 29 is curved inwardly towards a center of the battery 12 to providethe exposed region 30. In some embodiments, the curvature of the edge26, 28, 29 can substantially mirror the curvature of a finger, such as athumb, when the finger is used to hold the battery in place afterinserting the battery in a device such as a hearing aid. In variousembodiments, as shown in the figures, both the first and secondsidewalls 26, 28 are curved inwardly to provide two exposed surfaces 30of the battery 12. Referring to FIG. 7 illustrates an embodiment inwhich an end edge 29 of the tab is curved inwardly toward the center ofthe battery. For example, the radius of curvature of the first and/orsecond edge 26, 28, 29 can be about 0.1 mm to about 10 mm, about 1 mm toabout 5 mm, about 6 mm to about 10 mm, about 0.1 mm to about 1 mm, about1 mm to about 8 mm, and about 0.3 mm to about 1.5 mm. Other suitableradius of curvature include about 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7,0.8, 0.9, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8,8.5, 9, 9.5, and 10 mm. Where both the first and second side edges 26,28 are disposed inwardly to expose a portion 30 of the top surface 14,the first and second side edges 26, 28 can have the same or differentradii of curvature. Similarly, where the end edge 29 and one or both ofthe side edges 26, 28 are curved inwardly, the can have the same ordifferent radii or curvature.

About 5% to about 75% of the top surface 14 of the battery 12 can beexposed, with the remaining portion of the top surface 14 being coveredby the removable tab 16. Other suitable amounts of exposed top surface30 include about 10% to about 70%, about 15% to about 60%, about 5% toabout 10%, about 10% to about 20%, about 5% to about 50%. For example,about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, or 75% ofthe battery top surface 30 can be exposed. The amount of exposed topsurface 30 can depend in part, for example, on the type and size ofbattery. For example, the amount of exposed top surface 30 in metal/airbatteries, which include holes (not shown) in the top surface 14 thatmust be covered by the removable tab 16, may be dictated by the size andarrangement of the holes on the top surface 14.

Referring to FIG. 4, the overall length L of the tab 16 can varydepending on the size of the battery 12 to which the tab 16 is to beattached. In general, the removable tab 16 can have a length of about 8mm to about 40 mm, about 8 mm to about 15 mm, about 22 mm to 30 mm,about 25 mm to 35 mm, about 20 mm to 25 mm, and about 30 mm to about 35mm. Other suitable lengths include, for example, about 8, 9, 10, 11, 12,13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30,31, 32, 33, 34, 35, 36, 37, 38, 39, and 40 mm.

The battery cell attachment region 24 can have any suitable length L_(b)depending on the battery size to which the removable tab 16 is to beattached. In general, the battery cell attachment region 24 can have alength L_(b) that corresponds to the diameter D of the battery 12(illustrated in FIG. 6) to which it is attached. As examples, commonhearing aid battery diameters include about 5.8 mm, 7.9 mm, and 11.6 mm.The battery cell attachment region 24 can have substantially the same orthe same lengths in various embodiments. In some embodiments, thebattery cell attachment region 24 can extend in a parallel direction tothe top surface 14 past the circumferential edge 15 of the top surface14 of the battery 12, such that the length of the battery attachmentregion 24 is longer than the diameter of the battery 12 to which it isattached or adapted to be attached, so as to further facilitateapplication of a peeling force to the battery cell attachment region 24by twisting and/or pulling the removable tab 16 via the gripping region22 while concurrently holding the battery 12 in place in a device suchas a hearing aid by applying pressure to the exposed top surface 30. Ingeneral, the battery cell attachment region 24 can have a length ofabout 4 mm to about 15 mm, about 5 mm to about 10 mm, about 5.5 mm toabout 12 mm, about 4 mm to about 8 mm, and about 10 mm to about 15 mm.Other suitable lengths include about 4, 5, 6, 7, 8, 9, 10, 11, 12, 13,14, and 15 mm.

Referring again to FIG. 5, the battery cell attachment region 24 canhave a width W, as measured by a straight line extending from a centerpoint of the first edge 26 to a center point of the second edge 28 ofabout 0.2 to about 10 mm, about 0.5 mm to about 10 mm, about 0.7 toabout 5 mm, about 1 mm to about 9 mm, about 2 mm to about 8 mm, about 4mm to about 6 mm, about 5 mm to about 10 mm, or about 0.5 mm to about 6mm. Other suitable widths include about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7,0.8, 0.9, 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 mm. In the illustratedembodiment, the width is measured from a center point of curvature ofthe first edge 26 to a center point of curvature of the second edge 28.

Turning back to FIG. 4, the length L_(g) of the gripping region 22 canalso vary depending on the size of the battery to which the removabletab 16 is attached or adapted to be attached. For example, the grippingregion 22 can have a length of about 2 mm to about 35 mm, about 2 mm toabout 9 mm, about 4 mm to about 20 mm, about 10 mm to about 35 mm, about15 mm to about 30 mm, about 10 mm to about 20 mm, about 15 mm to about20 mm about 10 mm to about 15 mm, about 12 mm to about 18 mm, and about13 mm to about 17 mm. Other suitable lengths include about 2, 3, 4, 5,6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24,25, 26, 27, 28, 29, 30, 31, 32, 33, 34, and 35 mm.

For example, if the removable tab 16 is applied to a 675 size batterycell, the gripping region 22 can have a length L_(g) as measured fromthe circumferential edge 15 of the battery 12 of about 12.7 mm to about19.1 mm, or about 15.9 mm to the first tab end 18. In another exampleembodiment, the tab 16 can be applied to a smaller size button cell suchas a size 10 (which has a 5 mm diameter and a 3.5 mm height) or a size13 (having a 7 mm diameter and 5 mm height) cell. The removable tab 16can have the same gripping region length as for a 675 size cell, forexample. Different removable tab lengths can also be provided.

In the embodiments shown in the figures, the gripping region is directlyadjacent to the battery cell attachment region 24 and extends outwardlyfrom the circumferential edge of the battery 12. It is also contemplatedherein that the gripping region begins some distance away from thecircumferential edge of the battery, for example, where the battery cellattachment region extends beyond the circumferential edge of the batteryas described above. It is also contemplated herein that an intermediateregion can be provided between the battery cell attachment region 24 andthe gripping region 22.

The removable tab 16 can have a thickness of about 0.1 mm to about 1 mm,about 0.5 m to about 0.9 mm, about 0.2 mm to about 0.8 mm, about 0.4 mmto about 1 mm, about 0.3 mm to about 0.7 mm, or about 0.1 mm to about0.5 mm. Other suitable thicknesses include about 0.1, 0.2, 0.3, 0.4,0.5, 0.6, 0.7, 0.8, 0.9 and 1 mm.

The removable tab 16 can include any suitable materials or laminates.For example, the removable tab 16 can include thermoplastic materials.In an embodiment, the removable tab 16 can include a material selectedfrom the group consisting of biaxially-oriented polypropylene,polypropylene, polyethylene terephthalate, biaxially-orientedpolyethylene terephthalate, polyester, polyolefin, polyethylene, andcoextrusions, laminates, and other combinations thereof. Any number oflayers can be included in a laminate, such as adhesive layers, tielayers, print layers, strength or rigidity enhancing layers, foamlayers, and combinations thereof. For example, a removable tab 16 canhave a laminate structure as described in U.S. Pat. No. 6,329,095, thedisclosure of which is incorporated herein by reference.

In an embodiment, the removable tab 16 can include an adhesive in thebattery cell attachment region 24 for attaching the tab 16 to the topsurface 14 of the battery 12. In some embodiments, the adhesive canextend into the gripping region 22 and can be covered by a second layer,such as a kill tape (not shown), disposed over all or only a portion ofthe gripping region 22. Suitable adhesives include but are not limitedto pressure-sensitive adhesives, such as acrylic-basedpressure-sensitive adhesives.

In use, a consumer can grip the battery assembly at the gripping region22 of the removable tab 16 and insert the battery assembly 10 into thebattery compartment. The consumer can then apply a peel force to removethe removable tab 16, while applying pressure on the exposed portion 30of the top surface 14 of the battery 12 that is disposed between theedge 26, 28, 29 of the removable tab 16 and the circumferential edge 15.The ability to apply pressure to the top surface 14 of the batterydirectly, for example, using one's finger, advantageously allows theconsumer to stabilize the battery 12 in position in the batterycompartment while applying the peel force to remove the tab 16 andwithout interfering with the removal of the tab by having to alsodepress on a portion of the tab, as with conventional battery tabs.

In various embodiments, the removable tab 16 can be provided with atexturization layer or coating in the gripping region. For example, theremovable tab can have a coating or additional material layer applied tothe top or bottom surface of the main tab material in at least thegripping region 22. The texturized coating or layer can have an averagesurface roughness of about 0.6 microns to about 6 microns, about 0.8microns to about 1.8 microns, about 1 micron to about 2 microns, about0.7 microns to about 1.2 microns, about 0.8 microns to about 1 micron,about 0.6 microns to about 1.5 microns, or about 1.5 microns to about 2microns. Other suitable roughness includes about 0.6, 0.7, 0.8, 0.9, 1,1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5,2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4,4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9. 5, 5.1, 5.2, 5.3, 5.4, 5.5,5.6, 5.7, 5.8, 5.9, and 6 microns.

EXAMPLES

Six size 312 battery cell tabs in accordance with embodiments of thedisclosure were made. FIGS. 8a and 8b are photographs of one of thesetabs. The tab dimensions are provided in Table 1 below.

TABLE 1 Size 312 Battery Cell L₁- L₂-Non- L_(T) Total W_(T) W₁ - CellW₂ - Cell Adhesive adhesive Tab Tab width - width- length length lengthwidth widest narrowest Cell (mm) (mm) (mm) (mm) (mm) (mm) 1 9.50 16.0025.44 7.62 5.58 4.22 2 9.53 16.07 25.45 7.61 5.53 4.31 3 9.59 15.9025.46 7.65 5.64 4.49 4 9.73 15.84 25.53 7.6 5.55 4.33 5 9.66 15.93 25.517.7 5.52 4.43 6 9.72 15.93 25.51 7.73 5.45 4.09 Avg. 9.62 15.95 25.487.65 5.55 4.31 Std. Dev. 0.10 0.08 0.04 0.05 0.06 0.14

Six size 13 battery cell tabs in accordance with embodiments of thedisclosure were made. FIGS. 9a and 9b are photographs of one of thesetabs. The tab dimensions are provided in Table 2 below. FIG. 10Aillustrates the location of the dimensions listed in Tables 1 and 2 fora conventional battery cell, and FIG. 10B illustrates the location ofthe dimensions listed in Tables 1 and 2 for a tab in accordance with thedisclosure.

TABLE 2 Size 13 Battery Cell L₁- L₂-Non- L_(T) Total W_(T) W₁ - CellW₂ - Cell Adhesive adhesive Tab Tab width - width- length length lengthwidth widest narrowest Cell (mm) (mm) (mm) (mm) (mm) (mm) 1 9.41 16.1525.56 7.67 5.46 4.32 2 9.62 16.18 25.54 7.69 5.43 4.36 3 9.78 16.1825.44 7.7 5.46 4.3 4 9.46 16.3 25.54 7.59 5.51 4.38 5 9.42 16.23 25.527.71 5.5 4.32 6 9.41 16.12 25.49 7.64 5.42 4.27 Avg. 9.52 16.19 25.527.67 5.46 4.33 Std. Dev. 0.15 0.06 0.04 0.05 0.04 0.04

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any embodiment disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such embodiment.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present disclosure have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the disclosure. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this disclosure.

What is claimed:
 1. A battery assembly, comprising: a battery comprisinga top surface surrounded by a circumferential edge; and a removable tabattached to battery, the removable tab comprising: a first tab end, anoppositely disposed second tab end, and first and second oppositelydisposed sidewalls between the first tab end and the second tab end; agripping region disposed adjacent to the first tab end, the grippingregion being located outside of the circumferential edge of the battery;and a battery cell attachment region disposed adjacent to the second tabend, the battery cell attachment region being directly attached to thetop surface of the battery within the circumferential edge of thebattery, the battery cell attachment region including the second tab endthat is curved inwardly away from the circumferential edge of thebattery, while attached to the top surface of the battery, such that aportion of the top surface of the battery is exposed between the secondtab end and the circumferential edge of the battery.
 2. The batteryassembly of claim 1, wherein about 5% to about 75% of the top surface ofthe battery is exposed and the remaining portion of the top surface iscovered by the removable tab.
 3. The battery assembly of claim 1,wherein the second tab end has a radius of curvature of about 0.1 m toabout 10 mm.
 4. The battery assembly of claim 1, wherein the grippingregion has a length of about 10 mm to about 35 mm.
 5. The batteryassembly of claim 1, wherein the battery cell attachment region has awidth of about 0.2 mm to about 10 mm.
 6. The battery assembly of claim1, wherein the removable tab has a total length of about 8 mm to about40 mm.
 7. The battery assembly of claim 1, wherein the removable tabcomprises a material selected from the group consisting ofbiaxially-oriented polypropylene, polypropylene, polyethyleneterephthalate, biaxially-oriented polyethylene terephthalate, polyester,polyolefin, polyethylene, and coextrusions, laminates, and othercombinations thereof.
 8. The battery assembly of claim 1, furthercomprising a layer of an adhesive disposed between the battery cellattachment region and the top surface of the battery.
 9. The batteryassembly of claim 8, wherein the adhesive extends onto the grippingregion and the adhesive in the gripping region is covered by a killtape.
 10. The battery assembly of claim 1, wherein the removable tab hasa thickness of about 0.1 mm to about 1 mm.
 11. The battery assembly ofclaim 1, wherein the battery is a metal/air battery and comprises airholes in the top surface, and the battery cell attachment region isdisposed over and covers the holes.
 12. The battery assembly of claim11, wherein the metal/air battery is a zinc/air button cell.
 13. Thebattery assembly of claim 1, wherein the distance between second tab endto the circumferential edge is about 0.1 mm to about 10 mm.
 14. Thebattery assembly of claim 1, wherein a portion of the battery cellattachment region extends in a parallel direction beyond the top surfaceof the battery.
 15. A method of using the battery assembly of claim 1,comprising: gripping the battery assembly by the gripping region of theremovable tab; inserting the battery assembly into a batterycompartment; removing the removable tab by applying a peeling force tothe battery cell attachment region while applying pressure on theportion of the top surface of the battery exposed between second tab endand the circumferential edge.
 16. The method of claim 15, whereinpressure is applied by a user's fingertip.
 17. A removable tab,comprising: a first tab end and an oppositely disposed second tab end; agripping region disposed adjacent to the first tab end; a battery cellattachment region disposed adjacent to the second tab end, the batterycell attachment region being adapted to be attached to a top surface ofa battery, wherein the battery cell attachment region includes thesecond tab end that is curved inwardly such that a portion of a topsurface of the battery is exposed between the second tab end and acircumferential edge of the battery when the battery cell attachmentregion is attached to the top surface of the battery.
 18. The removabletab of claim 17, wherein the second tab end has a radius of curvature ofabout 0.1 mm to about 10 mm.
 19. The removable tab of claim 19, whereinthe gripping region has a length of about 10 mm to about 35 mm.
 20. Theremovable tab of claim 19, wherein the battery cell attachment regionhas a width of about 0.2 mm to about 10 mm